Thin-Film Battery Parallel Cell Architecture
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Solution Overview
Problem
Thin-film batteries face limitations in capacity scaling due to voltage constraints and require complex contacts for parallel connections, leading to high production costs and inefficiencies.
Innovation Solution
The method involves creating a stack structure of electrode and battery layers using unmasked deposition techniques, with porous or structured electrode materials and insulating layers to increase surface area and energy density, allowing for parallel connections without the need for electrical insulation between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery layers are connected in series to increase capacity, then the total voltage increases and capacity is improved, but the voltage quickly reaches the limits of available material and cannot be scaled indefinitely
Solution Approach 1:
The patent transitions from vertical stacking of battery layers (3D series connection) to lateral arrangement of battery cells in parallel on the substrate surface. This dimensional change allows capacity scaling without increasing voltage, as parallel connections add capacity while maintaining the same voltage level, thereby avoiding material voltage limits.
Solution Approach 2:
The patent divides the battery into multiple independent battery cells that are laterally arranged on the substrate. Each cell can be independently produced and connected in parallel, allowing modular scaling of capacity without the voltage accumulation problem inherent in series connections of stacked layers.
2Quantity of substance
If parallel connection of cells is implemented to increase capacity, then production costs per unit capacity are reduced, but complex contacts are required which need suitable production methods
Solution Approach 1:
The patent combines multiple battery cells into a single integrated thin-film battery structure on one substrate. The parallel connections between cells are formed using a simplified contact structure that shares common electrode regions, merging multiple connection paths into a unified design that reduces overall contact complexity compared to individually connected cells.
Solution Approach 2:
The electrode layers serve multiple functions: they act as both the active battery components and the connection contacts for parallel cell integration. The current collector and electrode materials are designed to provide both electrochemical functionality and electrical connection, eliminating the need for separate complex contact structures.
3Area of stationary object
If surface area is enlarged through substrate structuring to increase capacity, then more battery material can be deposited, but the production process becomes more complex with trenches and passivation
Solution Approach 1:
Instead of vertically stacking battery layers to increase capacity, the patent utilizes the lateral surface area of the substrate by arranging multiple battery cells in parallel on the same plane. This approach increases the effective battery area without requiring complex 3D substrate structuring, trenches, or additional passivation layers.
4Quantity of substance
If porous electrode materials are used to increase surface area and energy density, then capacity is enhanced, but the production process requires unmasked deposition techniques
Solution Approach 1:
The patent employs porous electrode materials and porous current collector structures to dramatically increase the effective surface area for electrochemical reactions. This porosity is achieved through unmasked deposition techniques where the porous structure forms naturally during the deposition process, eliminating the need for complex masking and patterning steps while enhancing energy density.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the capacity and energy density of thin-film batteries while reducing production costs by enabling scalable capacity increases and simplifying the construction process through the use of porous electrode materials and continuous or structured insulating layers.
Implementation Method 1
use of a metal layer, which is porous on the surface or else all the way through, but is conductive, for example a so-called platinum foam or platinum black
Implementation Method 2
application of a first unmasked flow of a first electrode material to the mount structure in order to form a first electrode layer on the mount structure
Data Source
AI summary
A method for production of a thin-film battery includes providing a mount structure, applying of a first unmasked flow of a first electrode material to the mount structure in order to form a first electrode layer, applying a second unmasked flow of a battery material in order to form a battery layer, and applying a third unmasked flow of a second electrode material in order to form a second electrode layer. The applying steps are repeated in order to produce a thin-film battery which consists of a plurality of first electrode layers, a plurality of battery layers, and a plurality of second electrode layers.